Haydale's Silar Cutting Tools: Where They Work Best

The selection of a ceramic cutting tool  & grade is an important factor to consider when planning a successful metalcutting operation.

Haydale’s silicon carbide (SiC) whiskers reinforce ceramic inserts to deliver world-class hardness and fracture toughness. The inclusion of SiC provides hardness second only to diamond. Due to long range force distribution provided by the fibre, we are able to achieve this result while maintaining exceptional toughness.

Ceramic cutting tools have excellent wear resistance at high cutting speeds and Haydale Ceramic Technologies (HCT), a world leading manufacturer of Silicon Carbide (SiC) ceramic materials, has the largest installed capacity for volume production across America, Europe and the APAC regions.

HCT developed the world’s first whisker reinforced tools, and continues to lead in materials engineering and innovation in this category.
​
Produced in Greer, South Carolina, their Silar® cutting tools are manufactured using the highest quality SiC products, particulate, fibers and microfibers.

​The inclusion of SiC whiskers provides hardness second only to diamond. Whisker-reinforced cutting tools offer both increased toughness and wear resistance, making them ideal for machining a variety of workpiece materials including Ni-based alloys, cobalt-based alloys, hardened steels, gray cast, ductile, nodular irons, and mill rolls.

​Cutting with reinforced or whiskered, ceramic inserts requires high surface speed and balanced feed rates.

Enhanced Silicon Carbide Cutting Tools

High cutting forces and high heat cause the metal to plasticize while the Silar ceramic substrate remains in-tact.

Whisker-reinforced cutting tools offer both increased toughness and wear resistance, making them ideal for machining a variety of workpiece materials including Ni-based alloys, cobalt-based alloys, hardened steels, ductile, and nodular irons, and mill rolls.

Silar cutting tools are designed for heavy material removal in roughing and semi-finishing applications and offer the perfect solution for high-speed machining of heat resistant super alloys.
​

• More than 10x the metal removal rate compared to traditional tungsten carbide cutting tools
• Excellent fracture resistance
• Increased hardness and toughness
• Extreme heat and wear resistance
• Dimensional stability
• New and novel CT-10 grade of whiskered tools that delivers superior surface finish compared to traditional whisker tools

Aerospace Cutting Tools

As demand for lightweight materials in the aerospace industry increases, Haydale can manufacture new grades and tooling that specialise in machining hard-to-cut materials.
​
With higher speed and feed rates, Silar cutting tools deliver consistent results and longer life in applications for:

• Rough turning (O.D. & I.D.)
• Semi finishing (O.D. & I.D.)
• Milling
• Grooving

Silar® whisker reinforced ceramic cutting tools are designed for heavy material removal in roughing and semi-finishing applications.
They offer the perfect solution for high-speed machining of heat resistant super alloys (HRSA) – Inconel, Waspalloy, Haynes, Monel, Rene, Incoloy, A-286, Nimonic, Udimet, etc.
​
The Silar® CT-25 Grade offers a comprehensive and advanced range of high-speed cutting tool solutions while Silar SBN570 is a high-content CBN grade specifically designed for finishing Heat-Resistant Super Alloys (HRSA's). The high CBN content in SBN570 ensures superior cutting performance and extended tool life when dealing with these challenging materials. It can withstand the high temperatures generated during machining, allowing for efficient and precise finishing operations.

Automotive Cutting Tools

It is essential for turning and milling tools in automotive applications to wear evenly with minimal maintenance in the most demanding applications.
To meet the workflow and high output demands, Haydale has a range of inserts for the automotive industry using SiC whiskers that are long-lasting and deliver consistent and reliable results as well as:

• High Fracture resistance for consistent cutting in interrupted and continuous operations
• High DOC capability (Max .100”)
• Speed capability of 2,400+ SFM in cast iron l Feed rate capability of .018” + IPR

Silar® inserts are designed for heavy DOC material removal in cast iron, compacted graphite iron (CGI), ductile iron, nodular iron, hardened steels (transmission components), white iron, chilled iron, and powdered metals. The high hardness allows Haydale to machine these extremely abrasive materials with extended tool life vs. traditional ceramics

Steel Mill Cutting Tools

Haydale’s steel mill inserts offer an optimal choice for milling fracking blocks and for milling flats on mill roll necks.
​
Steel mill geometries are used to remove heavy material in the most demanding rough turning conditions. Inserts are available for:

• Nodular iron mill rolls
• Hardened steel mill rolls
• Ductile iron mill rolls
• Stainless steel weld overlays / repair work on mill rolls
• Back up rolls
• D2 hardened tool steel

Haydale's Silar® inserts are designed for heavy DOC material removal in cast iron, compacted graphite iron (CGI), ductile iron, nodular iron, hardened steels (transmission components), white iron, chilled iron, and powdered metals.

If you would like to determine if Silar Ceramic cutting tools are right for your application, get in contact with us!